Modular building construction



June 2, 1970 D. COMM MODULAR BUILDING CONSTRUCTION 4 Sheets-Sheet 1Filed Feb. 14. 1968 2 WWEQ nvuav 7'0 Dmz'e f er 29% W W M arrawvsm//////////////&w?// r 6 v 4 D. COMM MODULAR BUILDING CONSTRUCTION June2, 1970 4 Sheets-Sheet 2 Filed Feb. 14, 1968 June 2, 1970 D. COMMMODULAR BUILDING CONSTRUCTION 4 Sheets-Sheet 5 Filed. Feb. 14. 1968 QNNWW QR nv we 7'02 June 2, 1970 D, coM 3,514,910

MODULAR BUILDING CONSTRUCTION Filed Feb. 14, 1968 4 Sheets-Sheet 43,514,910 MODULAR BUILDING CONSTRUCTION Daniel Comm, Highland Park,Ill., assignor to Dano Modules, Inc., a corporation of Delaware FiledFeb. 14, 1968, Ser. No. 705,391 Int. Cl. E041) 1/348; E04c 3/34 US. Cl.52-79 12 Claims ABSTRACT OF THE DISCLOSURE A building constructed from anumber of prefabricated modules. Each of the modules has solid spacingribs on its outer surface, which ribs cooperate with similar ribs onadjacent modules to define a series of spaces between adjacent modules.The modules are stacked and arranged according to a predeterminedbuilding plan, and selected spaces defined *by adjacent sets ofcooperating spacing ribs are filled with poured concrete to form supportcolumns for the building.

This invention relates to a building construction in which a number ofbuilding modules are arranged to form the structure.

ADVANTAGES OF THIS INVENTION There are numerous advantages to a systemin which prefabricated building modules are arranged to form a buildingstructure. For example, conventional building structures require theerection of forms, the insertion of reinforcing steel and the pouring ofconcrete to construct the building framework at the site. The modularconstruction of the present invention requires only a basic supportunderlying the entire building, and a conventional build ing frameworkis not required or used.

Additionally, the modular building construction of the present inventionobviates the problem of damage to mechanical facilities which oftenoccurs with prior art reinforced concrete systems. For example, in priorart systems, piping, conduit and duct work are generally installed inthe concrete forms before the concrete is poured. Often these componentswill be damaged during the pouring of the concrete, and in order torepair the damage after pouring, it is necessary to tear up theconcrete. In contrast, as is described below, with the modular buildingconstruction of the present invention, the mechanical facilities areinstalled after the modules are in place. In this manner, alterations orrepairs to mechanical facilities are simplified and can be made withouttearing up the concrete.

Furthermore, in accordance with the illustrative embodiment of thepresent invention, the modules are cast of concrete so that all interiorsurfaces are completely finished. Hence, there is no need to applyplaster or other wall surfacing to the interior walls of the modules.Such modules are fireproof, and the arrangement of-the modules accordingto the present invention provides excellent soundproof qualities.

In the illustrative embodiment, some of the modules are the size of asmall room so that they can be finished and equipped as a complete roomunit subsequent to casting thereof. Thus, these modules can be assembledat the site without need to install additional interior equipment. Theonly remaining installation required is the connecting of mechanicalfacilities.

Various other advantages of the modular building construction of thepresent invention will become apparent from the following descriptionthereof.

United States Patent SUMMARY OF THE INVENTION In accordance with thepresent invention, there is provided a building comprising a number ofprefabricated building modules having a horizontal wall member and atleast two opposing, vertically disposed side walls. Each of the moduleshas solid spacing means extending outwardly from the exterior surface ofat least one of the opposing side walls to provide space between thesides of adjacent modules. The solid spacing means of each module is incontact with the adjacent module to define chases for receiving aflowable, hardenable material, such as concrete. A flowable, hardenablematerial fills some but not all of the chases to connect adjacentmodules to each other and to provide support columns for the building.

The spacing means in the illustrative embodiment of the inventioncomprise ribs having the same lateral location on respective sides ofmodules. When modules are placed vertically, one above the other, thecontacting ribs of adjacent modules will form continuous vertical chasesfor receiving the flowable, hardenable material.

The use of support columns formed by pouring a flowable, hardenablematerial in selected chases defined between adjacent modules is uniqueand offers a modern structure with much air space between adjacentmodules. Hence, ready access between adjacent modules is provided sothat it is not necessary to drill through a thick wall if a serviceconnection is subsequently necessary between the modules. In contrast,prior art prefabricated systems such as disclosed in US. Pat. No.3,331,170 and French Pat. No. 1,269,080 require that concrete be pouredto fill all air spaces between adjacent modules. In such prior artsystems the modules must be relatively close to each otherotherwise theamount of concrete required to fill all air spaces would be very largeand prohibitively expensive. The relative closeness of adjacent modulesof such prior art systems does not allow much space for mechanicalfacilities, and in addition limits the soundproofing qualities of thestructure.

In the illustrative embodiment, the exterior surfaces of the opposingsides of the modules are bevelled with respect to a vertical plane. Thisexpedient achieves a positive mechanical purchase between the modulesand the hardened material between adjacent modules, and makes itpossible to provide the hardened material in only selected chasesbetween adjacent modules.

THE DRAWINGS A more detailed explanation of the invention is provided inthe following description and claims, and is illustrated in theaccompanying drawings, in which:

FIG. 1 is a perspective view of a building constructed in accordancewith the principles of the present invention;

FIG. 2 is a fragmentary perspective view of a single module about to bepositioned on a base structure;

FIG. 3 is an isometric view, partially exploded and partially inphantom, of a portion of the building of FIG. 1;

FIG. 4 is an enlarged fragmentary end elevation of a pair of buildingmodules in position adjacent each other;

FIG. 5 is a fragmentary end elevation of a number of building modulesafter they have been arranged and stacked to form a portion of abuilding structure;

FIG. 6 is a side elevation of a building construction with the modulesin place;

FIG. 7 is an enlarged fragmentary side elevation, taken partially insection, of a portion of the building construction of FIG. 6;

FIG. 8 is a top sectional view of a portion of one floor of a buildingof FIG. 1;

FIG. 9 is an enlarged fragmentary end elevation of four adjacent modulesin position with respect to each other with a transverse beam beingutilized; and

FIG. 10 is an enlarged fragmentary side elevation of a floor and ceilingconnection according to the principles of the present invention.

DESCRIPTION OF SPECIFIC EMBODIMENT The building illustrated in FIG. 1 isformed of a number of modules 22 which are stacked vertically andaligned horizontally. 'Each of these modules 22 is formed of pre-castreinforced concrete and has solid spacing ribs 24, 26 and 28 (best seenin FIGS. 4-6) integrally cast therewith and extending outwardly from theside walls 30, 32 and top wall 34. The spacing ribs of each module havethe same lateral location on respective side walls 30 and 32 and on topWall 34. In this manner, spacing ribs of adjacent modules can be placedin contact with each other and vertical chases will be formed betweenadjacent modules. Such chases provide air space to achieve soundproofingqualities and also within selected chases there is poured concretewhich, when hardened, provides support columns 110 for the structure.

The internal corners 36, 37, 38 and 39 are coved to achieve maximumstrength. The external surfaces 40 and 41 of side walls 30 nd 32 arebevelled with respect to a vertical plane (surface 41 being bevelledupwardly and outwardly), as shown most clearly in FIG. 4. This expedientis useful to provide a positive mechanical purchase when the concrete ispoured between the side walls of adjacent modules.

In the illustrative embodiment, the spacing ribs on the top wall 34 ofthe modules contact the exterior surface of the bottom wall, i.e., thefiat undersurface 45, of the module directly thereabove. The air spacesbetween vertically adjacent modules provide excellent soundproofingqualities and mechanical facilities can be provided in both the verticaland horiontal chases formed between adjacent modules. If desired,concrete may be poured to fill some of the horizontal chases and thusform horizontal beams extending between and supported by verticalsupport columns formed in vertical chases located on opposite sides of agiven module, which horizontal beams provide additional lateralstability for the vertical columns and, when the beams are in directcontact with the fiat undersurfaces 45 of the modules immediately above,help to support those vertically adjacent modules. As shown in FIG. 7,inserts 46 are provided to close the openings defined by verticallyadjacent modules. Trim 47 is connected to the otherwise exposed ends ofinserts 46 at the building facade, to provide an attractive appearance.

As best seen in FIGS. 4 and 9, the walls of each module define fourapertures 48, 49, 50 and 51 which extend the entire length of themodule, and are preferably located near the corners formed by adjoiningwalls of the module. These apertures are provided in a manner so thatwhen the modules are aligned end to end, the apertures defined by onemodule will register with the apertures defined by the adjacent modules,thereby providing openings for tie rods (see FIG. 6) connecting end toend modules to each other. Nuts 62 are screwed onto the ends of the tierods to retain them within the apertures. Such tie rods provideadditional support for the structure.

Where a hallway is desired, floor planks 66 and ceiling planks 68 may beinserted as shown most clearly in FIGS. 3 and 10. The floor and ceilingplanks also define apertures for receiving the tie rods 60; and the ends69 of the planks are cemented to the ends of the contacting modules(FIG. 10).

A typical floor plan is illustrated in FIG. 8, in which twelve modulesare aligned to provide an efficiency apartment 70 and a two-bedroomapartment 72-. The efiiciency apartment 70 includes a livingroom-sleeping area 76, a dining room-kitchen 78, an entrance hall and abathroom 82 The two-bedroom apartment 72 includes a living room-diningroom area 84, a kitchen 86, two bedrooms 88, 89, an entrance hall 90,two bathrooms 92, 93 a large walk-in closet 94 and a balcony 96.

The modular units are formed by pouring concrete into molds in which arepositioned the necessary reinforcing steel rods. After the modular unitsare formed, certain special components, including kitchen and bathroomcabinets, counter tops, plumbing fixtures, heating and air-conditioningsystems, windows and doors, ceramic tile, lighting fixtures, etc., areinstalled. The module can now be shipped to the site of construction andit can be placed in a predetermined position with all of the interiorfixtures already in place.

The construction of the building commences with the preparation of theunderlying support structure 42, as shown most clearly in FIG. 2. In theembodiment shown, structure 42 is poured in monolithic form. The firstmodule is then set in place, and any mechanical facilities which are tobe connected to the first unit or adjoining units are set in place.Reinforcing steel 98 is set in the areas in which structural columnswill be provided. In some in stances, transverse horizontal beams arerequired. To this end, some of the modules are formed with sections ofthe spacing ribs omitted, as shown in FIG. 9. In this manner, when tworows of adjacent modules have been aligned, mold members 101 and 102 areplaced in opening at the bottom thereof, reinforcing rods 103 are placedin the opening, and concrete is poured in the opening to providetransverse horizontal beams 104 that extend between and are supported byvertical support columns formed in vertical chases between horizontallyadjacent modules. To facilitate placement of the mold members, member101 may be trapezoidal in cross section and member 102 may be aparallelogram in cross section. They may be formed of any suitablefire-proof material.

Once the first unit is set in place, adjacent units are then set aroundit. Concrete is thereupon poured in the areas where reinforcing haspreviously been installed, to form support columns (best seen in FIGS.1, 3 and 6). Additional units are subsequently added, as called for inthe plans.

As a specific example, in the illustrated embodiment of the invention,the modules are twelve feet wide by eight feet high by ten feet deep.These dimensions can of course be varied without departing from theinvention. In the illustrative embodiment, each module is pro-cast ofreinforced concrete as a single monolithic unit. Such constructionprovides excellent fireproof quality and production efiiciency.

It is to be understood that the embodiment shown is for illustrativepurposes only, and many modifications or substitutions may be madewithout departing from the spirit and scope of the present invention.

What is claimed is:

1. A building which comprises: a gridwork of horizontal beams extendingthroughout the area underlying said building; means for supporting saidgridwork upon the ground; a plurality of horizontal rows ofprefabricated building modules at each of a plurality of floor levels insaid building, each of said prefabricated building modules having ahorizontal wall member and at least two opposing, vertically disposedside Walls, said horizontal wall member and vertical side wallsenclosing habitable space therebetween, the bottom rows of saidprefabricated building modules being supported at the first floor levelby said gridwork of horizontal beams, modules at all floor levels havingsolid spacing means extending outwardly from the exterior surface of atleast one of said opposing side walls to provide spaces between the sidewalls of all building modules and the immediately adjacent modules inall of said horizontal rows, solid spacing means on modules in each ofsaid horizontal rows being in contact with adjacent modules to definevertical chases that extend continuously from the bottom to the top ofsaid building, some of said continuous vertical chases being filled witha fiowable, hardenable material to form vertical support columns risingfrom said gridwork to the top of the building, the remainder of saidcontinuous vertical chases being devoid of said fiowable, hardenablematerial, selected ones of said latter chases containing utility linesfor servicing said building; and a plurality of horizontal beamsextending between and supported by said vertical support columns at eachfloor level of the building above said first floor level to provideadditional lateral stability for said vertical columns.

2. The building of claim 1 in which all said prefabricated buildingmodules in said building have solid spacing means as there describedextending outwardly from the exterior surface of at least one of theirsaid opposing side walls.

3. The building of claim 1 in which some of said prefabricated buildingmodules in said building have solid spacing means as there describedextending outwardly from the exterior surfaces of both their saidopposing side walls.

4. The building of claim 1 in which all said prefabricated buildingmodules in said building have said solid spacing means extendingoutwardlyfrom the exterior surfaces of both their said opposing sidewalls.

5. The building of claim 4 in which each of said solid spacing means isin contact with the solid spacing means of adjacent prefabricatedbuilding modules to define said vertical chases.

6. The building of claim 1 in which each of said prefabricated buildingmodules has a bottom wall and a top wall.

7. The building of claim 6 in which each of said top walls on saidprefabricated building modules carries solid spacing means to providehorizontally extending chases between the top of said module and thevertically adjacent module immediately above it, said horizontal chasesextending continuously from one side of said building to the other, someof said horizontal chases containing said fiowable, hardenable materialto form horizontal beams extending between and supported by saidvertical support columns, and the remainder of said horizontal chasesbeing devoid of said fiowable, hardenable material.

8. The building of claim 7 in which said solid spacing means on each topwall of said-prefabricated building modules is in contact with theexterior surface of the bottom wall of the vertically adjacent moduleimmediately above it and the continuously extending horizontal chasedefined thereby is completely filled with said fiowable, hardenablematerial to form a horizontal beam that is in contact with and helps tosupport said vertically adjacent module.

9. The building of claim 1 in which sections of said solid spacing meansare omitted, and mold means extending from the exterior surface of theside wall of one of said building modules to the exterior surface of theside wall of the adjacent module is positioned at the bottom of thespaces where said sections of the spacing means are omitted, to form achase extending continuously through said spaces from one side of thebuilding to the other, said horizontally extending chase being filledwith said fiowable, hardenable material to form a horizontal beamextending between and supported by said vertical support columns;

10. The building of claim 1 in which said fiowable, hardenable materialis poured concrete and said concrete is reinforced with steelreinforcing rods.

11. The building of claim 1 in which each of said prefabricated buildingmodules has a plurality of tie rods extending from one end of saidmodule into a horizontally adjacent module.

12. The building of claim 1 in which at least a portion of the exteriorsurface of each of said opposing side walls of all said prefabricatedbuilding modules is bevelled upwardly and outwardly with respect to avertical plane, to provide a positive mechanical purchase between saidside walls and the vertical support columns formed of flowable,hardenable material.

References Cited UNITED STATES PATENTS 1,421,278 6/ 1922 Matthews 524292,882,712 4/ 1959 Carlson 52429 1,900,457 3/1933 Miller 52437 2,009,2177/ 1935 Barnhart 52-437 3,260,025 7/ 1966 Van Der Lely 52228 3,287,86511/ 1966 Lockman 5279 3,292,327 12/1966 Van Der Lely 5279 3,331,1707/1967 Lowe 5279 3,377,755 4/1968 Stacky 5279 FOREIGN PATENTS 120,60912/ 1945 Australia.

269,000 1964 Australia.

722,341 1965 Canada.

120,024 1901 Germany.

HENRY C. SUTHERLAND, Primary Examiner US. Cl. X.R. 52--228, 236, 438

